Method and apparatus for producing individually contoured shoe insert

ABSTRACT

A method and apparatus for producing individually contoured shoe inserts. The apparatus scans a foot of a user and generates data signal representative of the shape of the scanned foot. The data signal is analyzed and modified by a processor based upon characteristics of the user&#39;s foot, qualities desired by the user and the manner in which the user walks. The modified data signals are provide to control an insert forming device which molds a blank template to produce an insert of a desired shape. The insert is provided to the user for the placement in a shoe. modified data may be stored in a memory device or on a recording medium for use at a future date to produce other inserts. Additional data for use in modifying the data signal may be provided by the user using a data input device such as a keyboard

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates generally to shoe inserts and, moreparticularly, to a method and apparatus for forming a customized shoeinsert conforming to a person's feet and/or compensating for defects ofthe person's feet. The present invention provides a method and apparatusfor digitizing the contour of the undersurface of a person's foot and toan improved system and method for forming such custom-made shoe inserts.

[0003] 2. Description of the Prior Art

[0004] Apparatuses, systems and methods for forming custom-made shoeinserts conforming to a person's feet and/or compensating for defects ofthe person's feet are disclosed, for example, in U.S. Pat. No. 4,454,618entitled SYSTEM AND METHOD FOR FORMING CUSTOM-MADE SHOE INSERT (issuedJun. 19, 1984), and in U.S. Pat. No. 4,876,758 entitled SYSTEM ANDMETHOD FOR FORMING CUSTOM-MADE SHOE INSERTS (issued Oct. 31, 1989). Inaccordance with such apparatus, systems and methods a foot impressionunit is employed for forming an impression of the undersurface of eachfoot. The foot impression unit includes a housing for supporting thefoot, an array of pins supported by the housing for controlled movementto operative positions in contact with the undersurface of the foot (ora sheet of flexible material disposed between the array of pins and thefoot) to form the impression, and a locking mechanism for thereuponlocking the pins in place to retain the impression. Additionally, thefoot impression unit may include provisions for holding a foot withdefects, such as pronation (an inward deflection of the foot),supination (an outward deflection of the foot), fallen arches or thelike, in a corrected position while forming and retaining an impressioncorrected for such defects. A pivotally-mounted sensing and shaping unitis either manually or automatically driven laterally and to-and-froacross both the retained impression and an insert blank to mechanicallysense the impression and to remove material from the blank inconformance with the sensed impression, thereby forming a custom-madeshoe insert from the blank.

[0005] Since the custom-made shoe insert is formed with a footsupporting surface substantially conforming to the undersurface of thevery foot for which the insert was formed, it provides better and morecomfortable foot support than is provided by conventional insoles andstandardized shoe inserts. Moreover, if the custom-made shoe insert wasformed from an impression corrected for foot defects, the custom-madeshoe insert will tend to compensate for those defects. However, adisadvantage of the foregoing apparatuses, systems and methods is thatthey employ a more expensive and less portable apparatus than desirableto facilitate their widespread adoption and usage in retail shoe stores,podiatrist's offices, and other such customer or patient servicelocations of the footware and footcare industries. This disadvantage isat least partly due to the fact that the foot impression unit hastypically been combined and employed together with the sensing andshaping unit at each customer or patient service location or has beentransported in its entirety from each such location, where an impressionis formed and retained, to a central shaping location, where the sensingand shaping unit is used for mechanically sensing the impressionretained by the foot impression unit and for shaping an insert blank inconformance with the sensed impression to form the custom-made shoeinsert.

[0006] Another disadvantage of the foregoing apparatuses for formingcustom-made shoe inserts, is that they employ a foot measuring unit forproducing electrical analog signals indicative of the contour of therear, side and upper surfaces of the foot and must therefore also employa converter to process those analog signals and convert them to recordedlaser/copy foot model data. This adds to the cost and the bulk of theapparatus employed at each customer or patient service location toobtain and record such data. Another disadvantage of the foregoingsystems and methods is that they do not provide for on-line modificationof the recorded laser/copy foot model data at the customer or patientservice location to compensate for defects of the foot visually observedat that location. Another disadvantage of the foregoing system andmethod is that they do not provide for locking the pins of the footmeasuring unit in place to retain an impression of the foot formed bythose pins. This precludes a visual inspection of the impression formedby the pins of the foot measuring unit to verify the accuracy of theimpression and to help in evaluating and discussing with the customer orpatient what modification of the recorded foot model data might be mostappropriate to compensate for defects of his or her foot. Still anotherdisadvantage of the forgoing systems and methods is that the attachmentof the pins to the moving elements of tubular variable capacitors andthe use of such tubular variable capacitors to determine thedisplacements of the pins adds to the complexity and reduces thepin-packaging of the contour measuring blocks. This increase both thecost and the bulk of the foot measuring unit, while decreasing theresolution and, hence, the quality of the impression formed by the footimpression unit.

[0007] Numerous types of methods for making individually contoured shoeinserts have been provide in the prior art. For example, the U.S.patents listed and described below all are illustrated of such priorart. While these units may be suitable for the particular purpose towhich they address, they would not be as suitable for the purposes ofthe present invention as heretofore described.

U.S. Pat. No. 6,000,082 Inventor: Nguyen Issued Dec. 14, 1999

[0008] A method for making a customized orthopedic device utilizing apre-made sole having a plurality of elongated members extending from thebottom of the sole and inserting each of the elongated members intoapertures of a cutting device. Once inserted through the apertures, thedistal tips of the elongated members contact a resistance layer whichresists the downward movement of the elongated members. A person's footis then rested on the topside surface of the insert; thereby depressingthe insert and elongated member tips into the resistance layer. Thecompressive force of the foot against the resistance layer tends toconfirm the insert about the plantar aspect of the foot. A cuttingmechanism is then used to cut the elongated members. The finishedproduct, is customized to the foot of the person and is ready to beinserted into a shoe

U.S. Pat. No. 5,275,775 Inventor: Riecken Issued: Jan. 4, 1994

[0009] An insert forming apparatus and method is provided for making aninsert to conformingly fit a shoe and a person's foot within the shoe.The method for practicing the invention includes using standard moldingtechniques to form a mold of the bottom of the last and using the moldto vacuum form a lower shell half that conforms to the bottom of thelast. With the lower shell half covering the mold and having vacuumcommunicating holes drilled therein, the last is placed in the lowershell half and the upper shell half is drawn down over the last andlower shell half by vacuum forming. When the upper and lower shellhalves have been formed, a hole is drilled in the lower shell half forinjecting curable material. A sheet of fabric or leather is placed overthe lover shell half, a person's foot is placed on the fabric or leatherin the lower shell half, and the upper shell half is placed over theperson's foot and fastened to the lower shell half. Curable material isthen injected into the lower shell half between the lower shell half andthe fabric or leather, thus forming an orthotic appliance that conformsto the shoe and to the person's foot.

U.S. Pat. No. 5,164,793 Inventor: Wolfersberger Issued Nov. 17, 1992

[0010] A shoe size selection system using a foot image to obtainmeasurement information in three dimensions leading to a proper shoesize recommendation. The system provides a computer program thatinterprets three-dimensional information about a foot and calculates thekey features that relate foot length and girth data that affect thecomfort and fit of a shoe. Apparatus is used to allow the computer toreproduce on a viewing screen the results of a scan of a foot and toindicate on a chart a preferred shoe size for a foot may be normal as tophysical form or abnormal as to physical form.

U.S. Pat. No. 5,128,880 Inventor: White Issued: Jul. 7, 1992

[0011] A method is provided for measuring bottom facing surfaces of footwhich comprises the steps of placing a foot against a reference surfacewithin the scanning field of the scanner, scanning bottom facingsurfaces of a foot, and electronically displaying the scan of the footbottom facing surfaces on a visual display to produce a scanned footimage articulating distances of portions of the foot bottom facingsurface from the reference surface. The electronically displaying stepmay further include assigning gray scale values to distances articulatedto produce a scan foot image comprising more than two gray scaleintensities so that a grey scale image with a stereoscopic appearance isprovided. Alternatively, the electronically displaying step may includeassigning color hues to the distances articulated to produce an imagecomprising more than two spectral hues so that a color image with astereoscopic appearance is provided. In addition, a method is providedfor measuring bottom facing surfaces of the foot which includes a stepof electronically displaying the scan of the foot bottom facing surfaceson a visual display to produce a scan foot image distinguishing regionsof the foot bottom facing surface exerting different pressures againstthe reference surface and assigning grey scale or color values to thefoot pressure regions. In addition, a system for topographically mappingbottom facing surfaces of a foot is provided.

U.S. Pat. No 4,876,758 Inventor: Rolloff Issued: Oct. 31, 1989

[0012] A foot impression unit is provided with an array of gaugingelements, a control mechanism for urging the gauging elements intocontact with the undersurface of a person's foot to form an impressionof the undersurface of the foot, a locking mechanism for releasablylocking the gauging elements in place to retain that impression, and asensing mechanism for scanning the gauging elements to producelaser/copy signals indicative of the positions of the gauging elements.These laser/copy signals are stored and processed by a computer toprovide a stored data record serving as a laser/copy representation ofthe impression of the undersurface of the foot. The computer may also beemployed to provide stored additional information for modifying thatdata record to compensate for a perceived defect of the foot. Inresponse to the stored data record and any stored additional informationfor modifying that data record, a shaping unit shapes an insert blank toform a custom-made shoe insert conforming to the undersurface of thefoot and compensating for any perceived defect of the foot.

U.S. Pat. No. 4,800,657 Inventor: Brown Issued: Jan. 31, 1989

[0013] Disclosed herein is an insert for a shoe, boot, or the like whichis capable of plural adjustments so as to adapt the insert to the uniquephysical conformation of the wearer's foot, to hold the foot in aneutral axis position substantially at all times, to return a foot intothe neutral axis mode automatically, and to provide a wide range ofsupport, resiliency, and angulation based on the needs of the user. Thedevice as set forth lends itself to modification for various sportswhere lateral motion is of primary importance, shock absorption andlongitudinal extension of the foot is of paramount importance, or forgeriatric patients whereby a single insert and the modifying devicesassociated therewith address the vast spectrum of orthopedic needs.

U.S. Pat. No. 4,745,927 Inventor: Brock Issued: May 8, 1988

[0014] An orthopedic shoe cushioned insert having a cushioned platemember with a first and second attachment means and a method ofoperation thereof are disclosed. Here, the cushioned plate member iscomprised of an upper and a lower plate member being attached togetherpreferably with a two-sided tape there between, as well as providing acushion effect thereof. The first attachment means is coupled therebelow the bottom front portion of the lower plate member for suitablywrapping around an ailing or injured toe. The second attachment means iscoupled there below the bottom back portion of the lower plate memberfor suitably wrapping around a foot. The orthopedic shoe cushionedinsert is reversible; i.e, usable for either a right or left foot, aswell as effective for managing arthritic ailments of toes or jointsthere of, such as “halux rigidus”, or the like.

U.S. Pat. No. 4,745,290 Inventor: Frankel Issued: May 17, 1988

[0015] The disclosure is directed to a method and apparatus for making acustom shoe based on non-contact measurements of a particular subject'sfoot. A foot is placed at an inspection position, and a laser beam isdirected at the foot, and scanned in a predetermined pattern over thesurface of the foot. The light beam reflected from the foot is detectedat a position detector. Surface coordinates of the foot are determinedas a function of the detector output. The determined surface coordinatesare stored and can then be used in making a shoe having a shape whichdepends on the stored coordinates. In a preferred embodiment, a rotatingscanner is disposed above the inspection position and an oscillatingreflector is disposed to one side of the inspection position. The beamof light is reflected from the rotating scanner to the oscillatingreflector to the foot, and the beam reflected from the foot isthereafter reflected back to the oscillating reflector, the rotatingscanner, and then the detector.

U.S. Pat. No. 4,503,576 Inventor: Brown Issued: Mar. 12, 1985

[0016] An orthopedic appliance and a method of making same in which theappliance is for use between a foot and a shoe, boot or the like andincludes an insert which is to be placed between the foot and the boot,the insert is to be custom formed to correspond to the contour of anindividual's foot. The insert is initially heated until its volumeexpands, thereafter the insert is placed on a platform and the two areadjoined to the foot. A vacuum bag is slid thereover, a vacuum is formedwithin the bag, and thereafter the insert takes the configuration of thebottom face of the foot. Additionally, foot pressure may be applied toaugment the degree of conformation of the insert to the foot, and inother embodiments an additional heel insert is placed below the majorinsert, and a crest piece is placed between the ball and toe area of theinsert on the underside thereof so that this additional material can bebonded to the major insert and also conform to the user's foot.

U.S. Pat. No 4,454,618 Inventor: Churchod Issued: Jun. 19, 1984

[0017] A system and method for forming a custom-made resilient insertfor a given person's shoe in which the contour of the support surface ofthe insert conforms to the contour of the undersurface of a person'sfoot.

SUMMARY OF THE PRESENT INVENTION

[0018] The present invention relates generally to shoe inserts and, moreparticularly, to a method and apparatus for forming a customized shoeinsert conforming to a person's feet and/or compensating for defects ofthe person's feet. The present invention provides a method and apparatusfor digitizing the contour of the undersurface of a person's foot and toan improved system and method for forming such custom-made shoe inserts.

[0019] A primary object of the present invention is to provide a methodand apparatus for producing individually contoured shoe inserts thatwill overcome the shortcomings of prior art devices.

[0020] Another object of the present invention is to provide a methodand apparatus for forming custom-made shoe inserts which is small insize and able to be positioned in a desired location for easy public useand access.

[0021] A further object of the present invention is to provide a methodand apparatus for forming custom made shoe inserts which is able toovercome the previously-mentioned and other disadvantages of theforegoing prior apparatuses, systems and methods.

[0022] A yet further object of the present invention is to provide amethod and apparatus for forming custom-made shoe inserts which is ableto facilitate more widespread adoption and usage of such methods and forthereby making custom-made shoe inserts more generally available to thepublic.

[0023] Another object of the present invention is to provide a methodand apparatus for forming custom-made shoe inserts which is lessexpensive and more reliable method for laser/copying the undersurface ofa person's foot.

[0024] A further object of the present invention is to provide a methodand apparatus for forming custom-made shoe inserts at a single centrallocation wherein the impression of the undersurface of the person's footis formed and scanned at a customer or patient service location to formthe laser representation of the impression, the laser representation isstored at the customer or patient service location and transmitted orsent to an adjacently located shaping location, and the custom-made shoeinsert is formed from the blank at the shaping location in accordancewith the stored laser representation and provided to the customer.

[0025] Another object of an aspect of the present invention is toprovide a method and apparatus for forming custom-made shoe insertswherein conventional copying equipment and techniques are utilized tocontrol the forming and scanning of the impression of the undersurfaceof the person's foot, the forming and storing of the laser/copyrepresentation of the impression, the transmitting of the stored laserrepresentation, and the forming of the custom-made shoe insert from theblank in accordance with the stored laser/copy representation.

[0026] Additional objects of the present invention will appear as thedescription proceeds.

[0027] A method and apparatus for producing individually contoured shoeinserts is disclosed by the present invention. The apparatus scans afoot of a user and generates a data signal representative of the shapeof the scanned foot. The data signal is analyzed and modified by aprocessor based upon characteristics of the user's foot, qualitiesdesired by the user and the manner in which the user walks. The modifieddata signals are provided to control an insert forming device whichmolds a blank template to produce an insert of a desired shape. Theinsert is provided to the user for placement in a shoe. The modifieddata may be stored in a memory device or on a recording medium for useat a future date to produce other inserts. Additional data for use inmodifying the data signal may be provided by the user using a data inputdevice such as a keyboard.

[0028] To the accomplishment of the above and related objects, thisinvention may be embodied in the form illustrated in the accompanyingdrawings, attention being called to the fact, however, that the drawingsare illustrative only, and that changes may be made in the specificconstruction illustrated and described within the scope of the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

[0029] Various other objects, features and attendant advantages of thepresent invention will become more fully appreciated as the same becomesbetter understood when considered in conjunction with the accompanyingdrawings, in which like reference characters designate the same orsimilar parts throughout the several views.

[0030]FIG. 1 is a perspective view of a person using the apparatus forforming custom-made shoe inserts of the present invention to produce ashoe insert;

[0031]FIG. 2 is a cross-sectional side elevation view of the footlaser/copy unit of the apparatus for forming custom-made shoe inserts ofthe present invention showing the foot impression unit being employed toform an impression of the undersurface of a persons foot;

[0032]FIG. 3 is a perspective view of a custom-made shoe insert formedby the apparatus for forming custom-made shoe inserts of the presentinvention;

[0033]FIG. 4 is a perspective view of the custom-made shoe insert ofFIG. 2 formed by the apparatus for forming custom-made shoe inserts ofthe present invention when shortened in length in accordance with a datarecord modification feature of the present invention;

[0034]FIG. 5 is block diagram illustrating the apparatus for formingcustom-made shoe inserts of the present invention; and FIG. 6A and 6Bare flow diagrams illustrating the method of forming custom-made shoeinserts using the apparatus for forming custom-made shoe inserts of thepresent invention.

DESCRIPTION OF THE REFERENCED NUMERALS

[0035] Turning now descriptively to the drawings, in which similarreference characters denote similar elements throughout the severalviews, the Figures illustrate the method and apparatus for formingcustom-made, individually contoured shoe inserts of the presentinvention. With regard to the reference numerals used, the followingnumbering is used throughout the various drawing figures.

[0036]10 customized shoe insert

[0037]12 foot

[0038]14 public area

[0039]16 patron

[0040]18 operator of apparatus for forming custom-made shoe inserts

[0041]34 laser/copy machine parts

[0042]40 foot laser/copy unit

[0043]50 apparatus for forming custom-made shoe inserts of the presentinvention

[0044]52 scanning lasers

[0045]54 processor

[0046]56 memory unit

[0047]58 shoe insert forming device

[0048]60 shoe insert storage device

[0049]62 output for customized shoe inserts

[0050]64 activation button

[0051]66 data input device

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0052] Turning now descriptively to the drawings, in which similarreference characters denote similar elements throughout the severalviews, FIGS. 1 through 6 illustrate the method and apparatus forproducing individually contoured shoe insert of the present invention,the apparatus being indicated generally by the numeral 50.

[0053] The method and apparatus for producing individually contouredshoe inserts 50 will now be described with reference to the figures. Inoperation, the method of producing an individually contoured shoe insertis simple and inexpensive for all persons thereby allowing individualsto quickly make custom contoured shoe inserts.

[0054] Referring now to FIG. 1, the apparatus for forming custom-madeshoe inserts 50 of the present invention is shown in a public area 14for use by patrons 16 to create a custom fitted shoe insert. A patron 16is shown placing a foot 12 on the foot laser/copy unit 40 for scanningby the apparatus for forming custom-made shoe inserts 50. An operator 18of the apparatus for forming custom-made shoe inserts 50 presses anactivation button 64 when the foot 12 of the patron 16 is correctlypositioned. Pressing of the activation button begins the process ofscanning the foot for producing the shoe insert. Once the foot 12 isscanned, a signal representative of the shape of the foot 12 is providedto a processor which analyzes the signal and generates a signalrepresentative of a shape for the shoe insert. When analyzing thesignal, the processor factors certain information including certainmodifications to the insert which may be required due to the manner inwhich the patron 16 walks. Such information includes whether the userrequires an insert which accounts for pronation (eversion) rampcorrection, supination (inversion) ramp correction, insert thicknessadjustment, pad/depression selection and placement adjustment, overallarch support adjustment, heel lift ramp adjustment, toe crest or sulcuslimit adjustment, or insert length adjustment. This information is usedto customize the insert to both the shape of the foot and the manner inwhich the user walks. The operator 18 may input data using a data inputdevice for use by the processor in modifying the shape of the insert tobe produced based upon certain characteristics of the patron's foot andthe manner in which the patron walks. The processor then controlsformation of the insert from a blank template and provides the custommade insert to the user.

[0055] The apparatus for forming custom-made shoe inserts 50 is shown inFIG. 2 and a block diagram of the apparatus for forming custom-made shoeinserts 50 is shown in FIG. 4. These figures show a foot laser/copy unit40 constructed in accordance with the preferred embodiment of theapparatus for forming custom-made shoe inserts 50 of the presentinvention and employed for digitizing a scan of the undersurface of aperson's foot 12. The foot laser/copy unit 40 includes standardcopy/laser machine parts 34 for forming an impression of theundersurface of the foot 12. When a user places a foot 12 on the footlaser/copy unit 40 as shown in FIG. 2, scanning lasers 52 as shown inFIG. 4 will scan the foot and provide a signal indicative of the shapeof the foot to a processor 54 upon activation of the button 64. Theactivation button 64 is connected to a processor 54 which controlsactivation of the foot laser/copy unit 40 and the scanning lasers 52.When the activation button 64 is pressed or activated in anyconventionally known manner, the processor 54 activates the footlaser/copy unit 40 and scanning lasers 52 to scan the foot 12 positionedthereon.

[0056] Once scanned, a signal indicative of the shape of the foot isprovided to the processor 54 from the foot laser/copy unit 40. Thesignal is analyzed by the processor 54 which generates a signalindicative of the shape of the insert to be produced. Modifying thesignal representative of the scanned shape of the foot may be desired tocompensate for one or more defects of the person's right foot. Any suchdefects may be detected and the required modifications of the storeddata record determined by visual inspection of the person's right foot,by visual inspection of the impression formed of the undersurface ofthat foot by the copy/laser machine parts 34, and by employing apparatusand techniques generally used in podiatry for this purpose. Whendetermining the shape of the insert the processor 54 thus considers theshape of the foot as well as information concerning whether the userrequires an insert which accounts for pronation (eversion) rampcorrection, supination (inversion) ramp correction, insert thicknessadjustment, pad/depression selection and placement adjustment, overallarch support adjustment, heel lift ramp adjustment, toe crest or sulcuslimit adjustment, or insert length adjustment. This information is usedto customize the insert to both the shape of the foot and the manner inwhich the user walks. The operator may also provide additionalinformation for the processor to consider when generating a modifiedsignal indicative of the shape of the insert to be produced using thedata input unit 66. The data input unit 66 may be in the form of akeyboard, touch screen, combination mouse and display screen, disk driveor other such data input device and allows certain criteria to be inputby the operator concerning the final shape of the insert. The signalgenerated by the processor 54 is then stored in the memory unit 56. Thestored data record so provided accordingly serves as a laser/copyrepresentation of the impression formed of the undersurface of theperson's right foot by laser/copy unit 40 and defines a custom-made shoeinsert 10, as shown, for example, in FIG. 2, conforming to theundersurface of that foot 12. The data stored in the memory unit 56 foreach foot and any corresponding additional information for modifyingthat data may be recorded on a floppy disc or similar data storingdevice or recording medium for future reference.

[0057] An insert produced to provide overall arch support adjustmentwhich compensates for arch problems, such as fallen arches, by modifyingthe stored data record as required to increase or decrease the height ofthe arch support provided by the custom-made shoe insert 10 shown inFIG. 3 by adjusting a selected percentage of the height of that support.

[0058] Adjusting the toe crest or sulcus limit adjustment provides aless confining fit by modifying the signal representative of the scannedfoot as required to reduce or remove the toe crest or sulcus that isdefined between the metatarsals and the toes and that would otherwise beformed is illustrated by the custom-made shoe insert 10 shown in FIG. 4.The length adjustment of the insert is employed to reduce the insert toa desired length and size shown by the insert illustrated in FIG. 4 maybe necessary for certain tight-fitting shoes. As a part of theinstruction for initiating the insert length adjustment, the userspecifies a desired amount by which the custom-made shoe insert 10should be shortened after it has been shaped. This specified amount maybe, for example, one-fourth full size, one-half full size, orthree-fourths full size (orthotic size).

[0059] The signal generated by the processor 54 is also used to controla shoe insert forming device 58 connected thereto. Upon receipt of asignal from the processor 54, the shoe insert forming device 58retrieves a blank template from a shoe insert storage unit 60 for use increating the insert. The shoe insert storage unit 60 stores a pluralityof blank templates used to produce shoe inserts therefrom. The shoeinsert forming device 58 then molds and cuts the blank template underthe control of the processor 54 to produce the shoe insert. An outputslot 62 is connected to the shoe insert forming device 58 for providingthe molded customized shoe insert to the patron

[0060] The operation of the apparatus for forming custom-made shoeinserts 50 will now be described with reference to the figures. Inoperation, the apparatus for forming custom-made shoe inserts 50 ispreferably positioned in a public area providing easy access for users.of the processor 54, the insert forming device 58 will form the blanktemplate into a customized shoe insert as described in step S 18 andprovide the insert 10 to the user as discussed in step S20. The userthen places the shoe insert in the shoe for which it was formed asstated in step S22 and is able to walk more comfortably and naturally.

[0061] From the above description it can be seen that the method ofproducing individually contoured shoe insert of the present invention isable to overcome the shortcomings of prior art devices by providing amethod of producing individually contoured shoe insert which is small insize, able to be positioned in a desired location for easy public useand access, facilitates more widespread adoption and usage of suchmethods and for thereby making custom-made shoe inserts more generallyavailable to the public and provides a more reliable method forlaser/copying the undersurface of a person's foot. The apparatus forforming custom-made shoe inserts is provided at a single centrallocation wherein the impression of the undersurface of the person's footis formed and scanned at a customer or patient service location to formthe laser representation of the impression, the laser representation isstored at the customer or patient service location and transmitted orsent to an adjacently located shaping location, and the custom-made shoeinsert is formed from the blank at the shaping location in accordancewith the stored laser representation and provided to the customer. Theapparatus for forming custom-made shoe inserts utilizes conventionalcopying equipment and techniques to control the forming and scanning ofthe impression of the undersurface of the person's foot, the forming andstoring of the laser/copy representation of the impression, the

[0062] When a user desires to have a shoe insert 10 produced, the userplaces a foot 12 on the foot laser/copy unit 40 as described in step S2.Once positioned on the foot laser/copy unit 40, the activation button 64is pressed to begin operation of the apparatus for forming custom-madeshoe inserts 50 as stated in step S4. Upon activation of the button 64,the processor 54 activates the foot laser/copy unit 40 and scanninglasers 52 to scan the shape of the foot 12 as discussed in step S6. Whenscanning the foot, the foot laser/copy unit 40 provides a data signalrepresentative of the shape of the foot to the processor 54 as describedin step S8.

[0063] Upon receipt of the data signal, the processor 54 analyzes thesignal as stated in step S10 and determines if the shape of the footindicates that the user pronates, supinates or requires some other formof corrective measures when producing the shoe insert 10 and modifiesthe data signal based upon this determination as described in step S12.Additionally, information may be entered by the user through the datainput device for use in modifying the data signal to thereby customizethe shoe insert 10. The modified data signal is then stored in thememory unit 56 for possible future use as discussed in step S14.

[0064] The apparatus for forming custom-made shoe inserts 50 is nowprepared to form the shoe insert. At this time the processor 54activates the insert forming device 58 to retrieve a blank template fromthe storage unit 60 as stated in step S 16. Under the controltransmitting of the stored laser representation, and the forming of thecustom-made shoe insert from the blank in accordance with the storedlaser/copy representation. Furthermore, the method of producingindividually contoured shoe insert of the present invention is simpleand easy to use and economical in cost to manufacture.

[0065] It will be understood that each of the elements described above,or two or more together may also find a useful application in othertypes of methods differing from the type described above.

[0066] While certain novel features of this invention have been shownand described and are pointed out in the annexed claims, it is notintended to be limited to the details above, since it will be understoodthat various omissions, modifications, substitutions and changes in theforms and details of the device illustrated and in its operation can bemade by those skilled in the art without departing in any way from thespirit of the present invention.

[0067] Without further analysis, the foregoing will so fully reveal thegist of the present invention that others can, by applying currentknowledge, readily adapt it for various applications without omittingfeatures that, from the standpoint of prior art, fairly constituteessential characteristics of the generic or specific aspects of thisinvention.

What is claimed is new and desired to be protected by Letters Patent isset forth in the appended claims:
 1. A method of producing a custom-madeshoe insert for a person's foot, said method comprising the steps of: a)scanning an undersurface of the person's foot to determine a shape ofthe foot; b) generating data signal indicative of the shape of the footscanned; c) modifying the data signal to compensate for a defect of theperson's foot; d) shaping a blank template in accordance with themodified data signal to form the costume-made shoe insert; and e)providing the costume-made insert to the person.
 2. The method as inclaim 1, further comprising the step of storing the modified data signalin a memory unit.
 3. The method as in claim 2, wherein the stored datasignal is further stored onto a recording medium.
 4. The method as inclaim 1, wherein modification of the data signal compensates for one ormore characteristics of the person's foot.
 5. The method as in claim 4,wherein said step of modification modifies a portion of the data signalrelated to a specified area of the scanned foot.
 6. The method as inclaim 4, wherein said step of modification modifies the data signal toalter a specified maximum height at the inside or outside of theperson's foot thereby producing a custom-made insert able to adjust theamount of arch support provided thereby.
 7. The method as in claim 4,wherein said information is operable for modifying the data signal inaccordance with a constant height adjustment.
 8. The method as in claim4, wherein said step of modification modifies a portion of the datasignal in accordance with a specified pad or depression of specifiedshape, size, position and thickness or depth.
 9. The method as in claim4, wherein said step of modification modifies a portion of the datasignal in accordance with a specified constant percentage increase ordecrease in height.
 10. The method as in claim 4, wherein said step ofmodification modifies a portion of the data signal in accordance with aspecified maximum height increase at the heel end of the person's foot.11. The method as in claim 4, wherein said step of modification modifiesa portion of the data signal by prompting an user to modify thecustom-made shoe insert in a specified manner.
 12. A device forproducing custom shoe inserts, said device including: a) means forscanning a foot of a user and generating a data signal representative ofthe shape of the scanned foot; b) means for modifying the data signalbased upon certain characteristics of the scanned foot; and c) means forforming an insert from a blank template based upon a control signal fromthe modifying means.
 13. The device as claimed in claim 12, furthercomprising means for inputting data to said modifying means for use inmodifying the data signal.
 14. The device as claimed in claim 13,wherein said inputting means is one of a keyboard, touch screen,combination mouse and display screen and disk drive.
 15. The device asclaimed in claim 12, further comprising means for storing the modifieddata signal for future use in producing additional inserts.
 16. Thedevice as claimed in claim 12, further comprising means for storing aplurality of blank templates for use in producing inserts a nd providingsaid blank templates to said forming means upon receipt of a controlsignal.
 17. The device as claimed in claim 12, wherein said scanningmeans includes lasers for scanning a foot of a user and means forgenerating the data signal representative of the shape of the scannedfoot based upon said scanning of the foot of the user.
 18. The device asclaimed in claim 12, further comprising means for delivering the insertfrom the forming means the user.